Gas presure regulator with a valve and piston assembly

ABSTRACT

A pressure regulator which includes a body. The body has inner walls defining an inlet port. Slidably moving within the inlet port is a hollow stem of a valve and piston assembly. The hollow stem is in slidable gas sealing contact with the inlet port. The valve and piston assembly includes a piston having a piston head with a valved opening therethrough. In the opening in the piston head is the arm of a plug. A body of the plug lies within the sliding piston held in place by a keeper spring, the keeper spring for maintaining a removed end of the plug arm against inner walls of the body. With such a structure, movement of the piston and valve assembly will be capable of unseating the plug from the valved opening in the piston allowing gas to flow from the hollow stem at the inlet port through an inner volume of the piston, through the valved opening of the piston head and into a regulated gas chamber defined in part by the inner walls of the body and an outer surface of the piston head.

This is a divisional of U.S. patent application Ser. No. 11/804,455,filed May 18, 2007, and claims priority therefrom and incorporates thatapplication herein.

FIELD OF THE INVENTION

Gas pressure regulators, namely, a piston-type gas pressure regulatorwith a valve in piston assembly for maintaining a set outlet pressurewhen the high pressure source drops.

BACKGROUND OF THE INVENTION

Gas pressure regulators have a number of uses. One such use of a gaspressure regulator includes providing a fixed output pressure from avariable high pressure inlet source. For example, a high pressure tankof breathing gas at 3000 psi may provide an output gas at 20 psi to adownstream device. However, one of the shortcomings of the prior art gaspressure regulators is that, as the high pressure source is depleted,the low pressure, even when set at a fixed value, may rise above thatvalue before the regulated valve shuts off the source. For example, as ahigh, variable pressure source gas initially at 3000 psi drops, throughuse, say to 800 psi, the initial set pressure for closure at thetransition or regulated valve can rise from its initial set pressure of,for example, 20 psi, to a higher pressure of, for example, 38 psi.

While in some applications this may not be a problem, other applicationsare sensitive to over pressurization from an initial set pressure.Therefore, there is a need for a gas pressure regulator in which the setpressure at the outlet port or in a regulated gas chamber does notchange materially with the drop in pressure of the high pressure gas.

OBJECTS OF THE INVENTION

It is one of several objects of the present invention to provide for apressure regulator which is capable of maintaining a set downstreamregulated pressure when engaged to a high pressure source whose highpressure may diminish in value through use.

SUMMARY OF THE INVENTION

One embodiment of Applicant's device includes a gas pressure regulatorwhich includes a body. The body has inner walls defining an inlet port.Slidably moving within the inlet port is a valve and piston assembly.The valve and piston assembly includes a hollow stem in slidable, gassealing contact with the inlet port. The valve and piston assemblyincludes a piston having a piston head with a valved openingtherethrough. Engaged with the opening in the piston head is a plughaving an arm, the arm extending through the valved opening. A body ofthe plug lies within the sliding piston held in place by a keeperspring, the keeper spring for maintaining a removed end of the plug armagainst the inner walls of the body.

With such a structure, movement of the piston and valve assembly will becapable of unseating the plug from the opening in the piston headallowing gas to flow from the hollow stem at the inlet port through aninner volume of the piston, through the valved opening of the pistonhead and into a regulated gas chamber defined in part by the inner wallsof the body and an outer surface or crown of the piston head.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cutaway view of one embodiment of Applicant's novel gaspressure regulator.

FIG. 1 a is a view of the valve and piston assembly of an embodiment ofthe pressure regulator.

FIG. 1 b is a view of the pressure regulator with the valve and pistonassembly removed therefrom.

FIG. 2 a is a cutaway view of another embodiment of Applicant's novelgas pressure regulator.

FIG. 2 b is a cutaway view of another embodiment of Applicant's novelgas pressure regulator.

FIG. 2 c is another embodiment of the pressure regulator.

FIG. 3 is an equipment drawing of a system showing a high pressure gassource and a low pressure gas receiving device, using Applicant's novelgas pressure regulator.

FIGS. 4 a and 4 b are top and side elevational views respectively of asystem using a high pressure source in a multiplicity of Applicant'snovel gas pressure regulators.

ELEMENT NUMERICAL DESIGNATIONS

-   10 Gas regulator-   12 Body-   14 First portion of body-   15 Regulated chamber-   16 Second portion of body-   18 Inner walls-   20 Engagement walls-   22 Stem guide walls-   24 Piston chamber walls-   26 Low pressure outlet walls of second portion 16-   28 Valve and piston assembly-   30 Main spring-   32 Piston head-   33 Crown of piston head-   34 O-ring (of piston head)-   35 Piston-   36 Plug-   37 Plug arm-   38 Seal-   39 Plug keeper spring-   40 Piston head opening-   41 Inner volume of piston-   42 O-ring-   43 Transition or regulator valve (equals 36, 38, 40, and 42)-   44 Piston body-   45 Piston stem port-   46 Piston stem-   48 Channel-   50 Transfer port-   51 System-   52 Spring set-   53 Receiving device-   54 Coupler-   55 High pressure source-   56 Body (nipple portion)-   57 Seat-   58 Outlet pressure adjustment mechanism-   60 Adjustment stem-   62 Adjustment stem knob-   70 Plug seal-   72 Manifold-   72 a High pressure source opening-   72 b High pressure source opening-   78 Membrane

FIG. 1 is a cross-sectional area of gas pressure regulator 10 comprisingbody 12. Body 12 may include, in one embodiment of the invention, firstportion 14 and second portion 16, the portions engaged, for example, bythreads.

Body 12 may have inner walls 18, including stem guide walls 22 defining,in part, piston stem port 45. Inner walls 18 may also include pistonchamber walls 24, and low pressure source walls 26.

A valve and piston assembly 28 is provided, which valve and pistonassembly is acted upon by a main spring 30, which main spring engagesinner walls 18 of body 12. A piston 35 includes a piston body 44 havinga piston stem 46 and a piston head 32 having a crown 33. The piston bodyhas a piston stem 46 for engagement with stem guide walls 22. Pistonbody 44 may be threadably engaged to piston head 32. O-ring 34 of pistonhead 32 is provided for a gas sealing engagement of piston head 32 withpiston chamber walls 24. Piston head 32 includes a valved piston headopening 40. Valved piston head opening 40 may also include, in part, aseal 38, typically cylindrical such as a Delrin seal that surroundsopening 40. Seal 38 may be elastomeric and act as a seat for receiving aplug 36 as set forth in more detail below. Piston stem 46 is hollow,having a channel 48, which channel is in fluid communication with wallsdefining an interior volume 41 of piston 35.

Valve and piston assembly 28 also includes the plug 36, the plug havinga plug arm 37, the plug arm 37 extending through valved piston headopening 40. The plug 36 may have a plug body 36 a including a conicalsection 36 b, which conical section 36 b may terminate at a plug arm 37.Plug keeper spring 39 acts against inner walls of piston 35 and plug 36so as to bias plug arm 37 towards seal 38 and against inner walls ofbody 12 at engagement walls 20 as seen in FIG. 1. That is, plug keeperspring 39 will assert a force against plug 36 so as to urge plug arm 37against inner walls of body 12, while piston 35 may move longitudinallyalong piston chamber walls to move valved piston head opening 40longitudinally back and forth in the piston chamber responsive topressure at piston stem port 45 and in regulated chamber 15 to seat andunseat plug 36.

A number of O-rings are provided, including O-ring 42, between seal 38and walls of piston head 32, O-ring 49 sealing walls of piston stem 46against walls of body 12, namely stem guide walls 22 and O-ring 34between the sliding piston head and body walls.

In operation, high pressure is provided at piston stem port 45, whichacts through channel 48, and inner volume 41 on valved opening 40 inpiston head 32. If the force asserted on the piston stem port and byspring 30 as seen in FIG. 1 (pushing the piston upward) is greater thanthe force pushing the piston downward, the piston will move up and, ifthe plug is seated against seal 38, will unseat and uncover piston headopening 40 to allow gas to enter a regulated chamber 15 defined by thepiston head crown 33 and some of the inner walls of piston body 12 seenin FIG. 1. As the regulated chamber fills, pressure will be asserted onthe piston crown to urge the piston in a downward direction as seen inFIG. 1 until it seats seal 38 against plug 36 closing valved opening 40.Here the forces will be substantially in balance.

To move the piston up as seen in FIG. 1, the force at piston stem 46must overcome the force applied by gas in the regulated chamber actingagainst the piston crown, as well as the slight force of plug spring 39.

Looking at the forces on the seal plug, Applicant's note the balancedforces

-   -   a. A_(s)=sealed area    -   b. B_(s)=supply fluid pressure    -   c. F_(s)=seal force on plug (F_(s)=A_(s)×B_(s))    -   d. F_(s)=F_(p)    -   e. A_(c)=area compression tube    -   f. F_(c)=force on compression tube    -   g. F_(c)=B_(s)×A_(c)    -   h. F_(c) varies with input pressure, ΔP_(s)    -   i. F_(x)+F_(c)=F_(rg)+F_(p), where F_(rg) is force of regulated        pressure, and F_(p) is force of stem. F_(s) is a constant (load        spring).

Therefore, F_(s)≈F_(p), which ≈F_(c); therefore, when there is a drop atF_(s)(ΔF_(s)), F_(p) drops as does F_(c). The valve is sensitive andresponsive, due in part, to the cross-sectional area of the piston stembeing about equal to valved opening 40.

FIGS. 2 a and 2 b illustrate two variations of Applicant's novel valveand piston gas pressure regulator.

FIG. 2 a illustrates that, in place of a single main spring, as shown inFIG. 1, a spring set 52 may be used. Two springs of the spring set 52are illustrated in the view shown in FIG. 2 a, but a multiplicity, heresix, would be provided in the full instrument. Sets may include two ormore springs. Each spring of spring set 52 is ideally materiallyidentical and the springs of the spring set are typically arrangedcircumferentially around a longitudinal axis of the piston betweenoutside walls of the piston and inner walls of the body. The use of amultiplicity of springs instead of a single spring is believed toachieve the benefits of better balance, sensitivity and accuracy,especially at low pressure; as well as the ability to provide a morecompact design.

FIG. 2 a also illustrates the use of a high pressure source couplingknob or coupler 54, which includes a threaded portion 54 a, and whichcoupler 54 is engaged with valve body 12, so it may freely rotate withrespect to the valve body. Further, a nipple portion 56 of valve body 12(engaged, for example, by threads) may be dimensioned to slideablyreceive the valve stem and define piston stem port 45. The use ofcoupler 54 allows one to hold the valve body 12 in a fixed position asthe coupler 54 rotatably engaged or disengaged with the threaded portionof a high pressure source, the threads for being engaged and bringingthe high pressure source into gas sealing relation with seat 57. Inother words, coupler 54 avoids the necessity of rotating the entire body12 of the gas pressure regulator onto the high pressure source, such asis required in the embodiment set forth in FIG. 1.

FIG. 1 illustrates a set pressure regulator. The value of the cutoffpressure may be set by taking into account the length of the plug armand the main spring length, as well as the main spring compressionfactor. For given plug arm length and main spring, movement ofengagement walls towards the piston crown will increase the cutoffpressure, requiring greater spring compression before the seat meets theplug to cut off flow through the valved opening.

FIG. 2 a also illustrates the use of an outlet pressure adjustmentmechanism 58, which may include an over pressurization relief port 59located in seat 63. Outlet pressure adjustment mechanism 58 includes anadjustment stem 60, adjustment stem knob 62, and adjustment stem seal64, defining relief port 59. Stem knob 62 is in slotted engagement withadjustment stem 60. Rotating knob 62 will slide stem 60 longitudinally.

As can be seen in FIG. 2 a, plug arm 37 engages relief port 59. Further,it is seen that adjustment stem knob 62 is rotationally engaged to thefirst portion of the valve body so as to rotate about the valve body.Moreover, a near end of adjustment stem 60 has a seat 63. A near end ofadjusting stem 60 is threadably engaged with first portion 16 of valvebody 12. Thus, when stem knob 62 (which is fixedly attached to adjustingstem 60) is rotated, it will cause adjusting stem 60 to rotate, whichbeing threadably engaged to first portion 16 of valve body 12 will movethe seat 63 with relief port 59 longitudinally. Such movement willchange the distance between the piston head and relief port 59. Asdiscussed above, for a given plug arm dimension, changing the distancefrom the engagement walls, here defining relief port 59, and the valvedopening 40 will change the setting of the outlet pressure valve. Thus,FIG. 2 a illustrates a manner in which the outlet pressure may beselectively set. Further, FIG. 2 a illustrates the use of engagementwalls 20 defining a relief port 59, which relief port allows for therelief of gas in an overpressurization system that may occur downstreamof regulated chamber 15 by allowing gas to escape through relief port 59and out relief port vent channel 61.

FIG. 2 b illustrates the use of Applicant's valve and piston assemblywith an adjusting stem 60 that has, instead of an adjusting knob, ascrewdriver slot 66 which, when engaged to a screwdriver allows theadjustable stem 60 to be rotated as in the embodiment set forth in FIG.2 a, but includes a locknut 68 which, when the desired cutoff pressureis selected by positioning adjustable stem 60 with respect to the valvebody, locknut 68 can be rotated down tight onto the valve body toprevent rotation of adjustable stem 60 and subsequent loss of proper setvalue.

FIG. 2 b also illustrates plug seal 70 that may be used to seal highpressure source port opening as it is positioned longitudinally in theother embodiments and provide, for example, two high pressure sourceopenings 72 a and 72 b laterally with respect to a longitudinal axis ofthe body, as seen in FIG. 2 b.

FIG. 2 c illustrates another preferred embodiment of Applicant's novelgas regulator 10. In this embodiment, a difference is the use of aflexible fluid sealing membrane 78, which seals a gap between pistonhead 32 and inner walls 18 of body 12. It is noted in the embodimentillustrated in FIG. 2 c, that the frictional forces found in the earlierembodiments where the piston head and O-ring slide along the inner walls18 are avoided—yet there is in fact an effective seal generated by fluidsealing membrane 78. Thus, it is believed that even further sensitivitymay be achieved with this embodiment. Note that this embodiment may beused with one or more of the features illustrated in other embodiments.Fluid sealing membrane 78 may be made from a number of suitablematerials, such as, for example, steel mesh reinforced rubber or fabricreinforced rubber or the like. Indeed a thin steel sheet may be used.Membrane 78 acts as a “bellows” in this embodiment. Thus, the embodimentillustrated in FIG. 2 c may utilize a diaphragm action for cutoff.

The O-ring between the piston head 32 and inner walls 18 of the body 12or the flexible membrane 78 or other means known in the art may define afluid sealing means between the piston head and the inner walls of thebody. A sealing means (hydraulic or pneumatic) will function to seal offa regulated chamber which is in fluid communication with the highpressure source through the valved opening and also a low pressuredevice downstream.

The use of any of the embodiments disclosed herein provide for lowpressure accuracy, sensitivity and repeatability, for example, down to 5to 7 lbs. on a ⅛ inch diameter piston, that in the prior art wouldtypically require a larger piston diameter. The use of a flexiblesealing member provides the ability to get greater area on the pistonface, removes friction of the O-rings, and may provide betterperformance and increased accuracy at low pressure.

FIG. 3 illustrates a system 51, which system 51 provides for a regulatedtransfer of gas from a high pressure source 55 to a regulated gasreceiving device 53 through Applicant's novel gas pressure regulator 10which has a valve in piston structure to compensate for a drop inpressure at high pressure source 55 as receiving device 53 uses the highpressure source gas, which structure allows the receiving device tocontinue to receive gas from the high pressure source at the presetpressure value. The high pressure sources may include: oxygen, abreathable gas, an inert gas, CO₂, N₂, argon, nitrous oxide or any othergas or fluid Receiving devices may include: a wine bottle, tool or anyother device. The receiving device may also include a helmet for use byan astronaut, race car driver or underwater diver wherein the highpressure source is a tank containing a breathable gas.

FIGS. 4 a and 4 b illustrate two views of the system in which amultiplicity of Applicant's novel regulator 10 (see FIG. 2 b) are usedwith a manifold 74 and a high pressure supply. In this manner, one ormore single high pressure supplies can provide low pressure gas to twoor more low pressure receiving devices with the use of manifold 74,which manifold would have inner channels that will supply fluid from thehigh pressure supply line, which is engaged to the walls of the manifoldto the low pressure users through Applicant's novel gas regulators 10.In the system illustrated, the first gas pressure regulator is set at afirst cutoff pressure, here 50 lbs., at a second pressure, here 65 lbs.,and the third at a third pressure, here 150 lbs.

Although the invention has been described in connection with thepreferred embodiment, it is not intended to limit the invention'sparticular form set forth, but on the contrary, it is intended to coversuch alterations, modifications, and equivalences that may be includedin the spirit and scope of the invention as defined by the appendedclaims. For example, gas is considered to be a fluid, the device mayoperate with either a liquid or a gas.

1. A system for the regulated transfer of gas, the system comprising: atleast one upstream high pressure gas source; at least one downstream gasreceiving device for receiving gas at a pressure lower than that of thehigh pressure gas source; and at least one regulator engaging theupstream source and downstream device including a valve and pistonassembly adapted to compensate for drop in the high pressure gas sourcewhile providing receiving device at a set pre-selected pressure.
 2. Thesystem of claim 1, wherein the gas pressure regulator includes: a bodyand a valve in piston assembly, the body having a longitudinal axis andinner walls, the inner walls defining at least engagement walls, pistonchamber walls, piston stem guide walls, and a piston stem port; aspring; and a valve and piston assembly, including a piston having abody and piston head, the piston body having a piston stem, the pistonstem having a compensating tube therein, the piston head having a valvedopening, the piston body also having an inner volume in fluidcommunication with the compensating tube and the valved opening, thepiston and valve assembly further including a plug, the plug having aplug body dimensioned for receipt substantially within the inner volumeof the piston body and a plug arm, the plug arm extending through thevalved opening past the piston head for engagement with the engagementwalls of the body, the valve and piston assembly further including akeeper spring for acting between the piston body and the plug to urgethe plug against the engagement walls of the body; wherein the piston isbiased towards engagement walls by the spring; wherein the piston stemis in sliding engagement with the piston stem guide walls, such that achange in pressure at the piston stem port may move the piston withrespect to the body, thus moving the valved opening in relation to theplug and allowing a gas to move between the inlet port through the stem,through the inner volume of the piston through the valved opening intothe regulated chamber.
 3. The system of claim 1, further including atleast two regulators and a manifold, the manifold for engaging theupstream high pressure gas source and two or more regulators and atleast two downstream gas receiving devices.
 4. The system of claim 1,wherein the upstream gas source is a high pressured tank containing atleast one of the following: CO₂, N₂, argon, and nitrous oxide.
 5. Thesystem of claim 1, wherein the downstream gas receiving device includesone of the following: wine bottle, pneumatic tool, and helmet.
 6. Thesystem of claim 3, wherein the gas pressure regulator includes: a bodyand a valve in piston assembly, the body having a longitudinal axis andinner walls, the inner walls defining at least engagement walls, pistonchamber walls, piston stem guide walls, and a piston stem port; aspring; and a valve and piston assembly, including a piston having abody and piston head, the piston body having a piston stem, the pistonstem having a compensating tube therein, the piston head having a valvedopening, the piston body also having an inner volume in fluidcommunication with the compensating tube and the valved opening, thepiston and valve assembly further including a plug, the plug having aplug body dimensioned for receipt substantially within the inner volumeof the piston body and a plug arm, the plug arm extending through thevalved opening past the piston head for engagement with the engagementwalls of the body, the valve and piston assembly further including akeeper spring for acting between the piston body and the plug to urgethe plug against the engagement walls of the body; wherein the piston isbiased towards engagement walls by the spring; wherein the piston stemis in sliding engagement with the piston stem guide walls, such that achange in pressure at the piston stem port may move the piston withrespect to the body, thus moving the valved opening in relation to theplug and allowing a gas to move between the inlet port through the stem,through the inner volume of the piston through the valved opening intothe regulated chamber.
 7. The system of claim 4, wherein the gaspressure regulator includes: a body and a valve in piston assembly, thebody having a longitudinal axis and inner walls, the inner wallsdefining at least engagement walls, piston chamber walls, piston stemguide walls, and a piston stem port; a spring; and a valve and pistonassembly, including a piston having a body and piston head, the pistonbody having a piston stem, the piston stem having a compensating tubetherein, the piston head having a valved opening, the piston body alsohaving an inner volume in fluid communication with the compensating tubeand the valved opening, the piston and valve assembly further includinga plug, the plug having a plug body dimensioned for receiptsubstantially within the inner volume of the piston body and a plug arm,the plug arm extending through the valved opening past the piston headfor engagement with the engagement walls of the body, the valve andpiston assembly further including a keeper spring for acting between thepiston body and the plug to urge the plug against the engagement wallsof the body; wherein the piston is biased towards engagement walls bythe spring; wherein the piston stem is in sliding engagement with thepiston stem guide walls, such that a change in pressure at the pistonstem port may move the piston with respect to the body, thus moving thevalved opening in relation to the plug and allowing a gas to movebetween the inlet port through the stem, through the inner volume of thepiston through the valved opening into the regulated chamber.
 8. Thesystem of claim 1, wherein the gas pressure regulator includes: a bodyand a valve in piston assembly, the body having a longitudinal axis andinner walls, the inner walls defining at least engagement walls, pistonchamber walls, piston stem guide walls, and a piston stem port; aspring; and a valve and piston assembly, including a piston having abody and piston head, the piston body having a piston stem, the pistonstem having a compensating tube therein, the piston head having a valvedopening, the piston body also having an inner volume in fluidcommunication with the compensating tube and the valved opening, thepiston and valve assembly further including a plug, the plug having aplug body dimensioned for receipt substantially within the inner volumeof the piston body and a plug arm, the plug arm extending through thevalved opening past the piston head for engagement with the engagementwalls of the body, the valve and piston assembly further including akeeper spring for acting between the piston body and the plug to urgethe plug against the engagement walls of the body; wherein the piston isbiased towards engagement walls by the spring; wherein the piston stemis in sliding engagement with the piston stem guide walls, such that achange in pressure at the piston stem port may move the piston withrespect to the body, thus moving the valved opening in relation to theplug and allowing a gas to move between the inlet port through the stem,through the inner volume of the piston through the valved opening intothe regulated chamber; further including at least two regulators and amanifold, the manifold for engaging the upstream high pressure gassource and two or more regulators and at least two downstream gasreceiving devices; wherein the upstream gas source is a high pressuredtank containing at least one of the following: CO₂, N₂, argon, andnitrous oxide.
 9. The system of claim 8, wherein the downstream gasreceiving device includes one of the following: wine bottle, pneumatictool, and helmet.